Simultaneous topology and fastener layout optimization of assemblies considering joint failure

Abstract: This paper provides a method for the simultaneous topology optimization of parts and their corresponding joint locations in an assembly. Therein, the joint locations are not discrete and predefined, but continuously movable. The underlying coupling equations allow for connecting dissimilar meshes and avoid the need for remeshing when joint locations change. The presented method models the force transfer at a joint location not only by using single spring elements but accounts for the size and type of the joints. When considering riveted or bolted joints, the local part geometry at the joint location consists of holes that are surrounded by material. For spot welds, the joint locations are filled with material and may be smaller than for bolts. The presented method incorporates these material and clearance zones into the simultaneously running topology optimization of the parts. Furthermore, failure of joints may be taken into account at the optimization stage, yielding assemblies connected in a fail-safe manner.